U.S. patent application number 10/291383 was filed with the patent office on 2003-04-10 for imaging apparatus and improved toner therefor.
Invention is credited to Ben-Avraham, Peretz, Bossidan, Becky, Landa, Benzion, Lavon, Amiran.
Application Number | 20030068570 10/291383 |
Document ID | / |
Family ID | 11066705 |
Filed Date | 2003-04-10 |
United States Patent
Application |
20030068570 |
Kind Code |
A1 |
Landa, Benzion ; et
al. |
April 10, 2003 |
Imaging apparatus and improved toner therefor
Abstract
The invention relates to a liquid toner and imaging apparatus
provided with an imaging surface having a liquid toner image formed
thereon on fibrous toner particles and carrier liquid. The fibrous
toner particles can be composed of a polymer portion and pigment
dispersed therein, where the polymer portion comprises a surface of
the fibrous toner particles and is insoluble in the carrier liquid
at temperatures below 40.degree. C., so that the polymer portion
will not dissolve or solvate in storage. The polymer portion also
is solvatable by the carrier liquid only at temperatures above
50.degree. C. The carrier liquid has, as a major component, first
liquid hydrocarbon having a first rate of evaporation, and, as a
minor component, second liquid hydrocarbon having a second rate of
evaporation which, at room temperature, is at least an order of
magnitude less than the first rate of evaporation.
Inventors: |
Landa, Benzion;
(Kfar-Abaron, IL) ; Ben-Avraham, Peretz; (Rehovot,
IL) ; Bossidan, Becky; (Rishon-Lezion, IL) ;
Lavon, Amiran; (Bat-Yam, IL) |
Correspondence
Address: |
KENYON & KENYON
1500 K STREET, N.W., SUITE 700
WASHINGTON
DC
20005
US
|
Family ID: |
11066705 |
Appl. No.: |
10/291383 |
Filed: |
November 12, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10291383 |
Nov 12, 2002 |
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08809419 |
Jun 5, 1997 |
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6479205 |
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08809419 |
Jun 5, 1997 |
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PCT/NL95/00030 |
Jan 20, 1995 |
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Current U.S.
Class: |
430/116 ;
399/237; 430/45.2 |
Current CPC
Class: |
G03G 9/125 20130101;
G03G 15/10 20130101; G03G 9/13 20130101; G03G 15/162 20130101 |
Class at
Publication: |
430/116 ;
399/237; 430/45 |
International
Class: |
G03G 009/125 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 28, 1994 |
IL |
111440 |
Claims
1. Imaging apparatus comprising: an imaging surface having a liquid
toner image formed thereon, said image comprising toner particles
and carrier liquid, wherein the carrier liquid comprises as a major
component, a liquid that evaporates relatively quickly at room
temperature, and as a minor component, a liquid that evaporates
relatively slowly at room temperature; and an intermediate transfer
member having a release outer layer that receives the toner image
from the imaging surface and from which it is subsequently
transferred.
2. Imaging apparatus according to claim 1 wherein said minor
component comprises between 0.2 and 2% and wherein said major
component comprises between 98% and 99.7% of the total amount of
said carrier liquid.
3. Imaging apparatus according to claim 1 or claim 2 wherein the
major component evaporates at least about an order of magnitude
more quickly than the minor component.
4. Imaging apparatus according to any of the preceding claims
wherein major component has a vapor pressure at 100.degree. F. of
greater than 0.05 psia when measured according to ASTM standard D
2879.
5. Imaging apparatus according to any of the preceding claims
wherein the release outer layer solvates the carrier liquid.
6. Imaging apparatus according to any of the preceding claims
wherein at least one of said carrier liquid components is a liquid
hydrocarbon.
7. Imaging apparatus according to any of the preceding claims
wherein both of said carrier liquid components are liquid
hydrocarbons.
8. A liquid developer comprising: toner particles; and carrier
liquid, wherein the carrier liquid comprises as a major component,
a liquid that evaporates relatively quickly at room temperature,
and as a minor component, a liquid hydrocarbon that evaporates very
slowly at room temperature.
9. A liquid toner according to claim 8 wherein said minor component
comprises between 0.2 and 2% and wherein said major component
comprises between 98% and 99.7% of the total amount of said carrier
liquid.
10. A liquid toner according to claim 8 or claim 9 wherein the
major component evaporates at least about an order of magnitude
more quickly than the minor component.
11. A liquid toner according to any of claims 8-10 wherein major
component has a vapor pressure at 100.degree. F. of greater than
0.05 psia when measured according to ASTM standard D 2879.
12. A liquid toner according to any of claims B-11 wherein at least
one of said carrier liquid components is a liquid hydrocarbon.
13. A liquid toner according to any of claims 8-12 wherein both of
said carrier liquid components are liquid hydrocarbons.
14. A mixture of liquid hydrocarbons substantially comprising
between 0.5 and 4% of a substantially non-conducting liquid that
evaporates very slowly at room temperature and between 96% and
99.5% of a substantially non-conducting liquid that evaporates at
least an order of magnitude more quickly.
15. A mixture according to claim 14 wherein said mixture further
comprises a charge director for liquid toner articles.
16. A mixture according to claim 14 or claim 15 wherein at least
one of said carrier liquid components is a liquid hydrocarbon.
17. A mixture according to any of claims 14-16 wherein both of said
carrier liquid components are liquid hydrocarbons.
Description
RELATED APPLICATIONS
FIELD OF THE INVENTION
[0001] The present invention relates to image forming and image
transfer apparatus especially for use in electrostatic imaging
using an intermediate transfer blanket and to toner materials
especially useful for electrostatic imaging using an intermediate
transfer member.
BACKGROUND OF THE INVENTION
[0002] The use of an intermediate transfer member in electrostatic
imaging is well known. Generally, toner materials for use with such
blankets are similar to those used for direct transfer from a
photoreceptor to a final substrate, such as paper.
[0003] Various types of intermediate transfer members are known and
are described, for example in U.S. Pat. Nos. 3,862,848, 4,684,238,
4,690,539, 4,531,825, 4,984,025, 5,047,808, 5,089,856, 5,335,054,
U.S. patent applications U.S. Ser. No. 08/116,198, METHOD AND
APPARATUS FOR IMAGING USING AN INTERMEDIATE TRANSFER MEMBER, filed
Sep. 3, 1993, now U.S. Pat. No. 5,636,349; U.S. Ser. No.
07/400,717, METHOD AND APPARATUS FOR IMAGING USING AN INTERMEDIATE
TRANSFER MEMBER, filed Aug. 30, 1989, now U.S. Pat. No. 5,555,185;
U.S. Ser. No. 08/115,803 LIQUID DEVELOPER IMAGING SYSTEM HAVING A
HEATED INTERMEDIATE TRANSFER MEMBER, filed Sep. 3, 1993, now U.S.
Pat. No. 5,572,274; U.S. Ser. No. 07/351,546 COLOR IMAGING SYSTEM,
filed May 15, 1989, now U.S. Pat. No. 5,557,376 and U.S. patent
application Ser. No. 08/321,538 filed Oct. 11, 1994 titled IMAGING
APPARATUS AND INTERMEDIATE TRANSFER MEMBER THEREFOR to David EDAN
et al., the specifications of all of which are incorporated herein
by reference.
[0004] Removable intermediate transfer blankets for attachment to a
drum for use in electrostatic images are described in a number of
the above referenced patents and applications.
[0005] It has been found that the lifetime of such blankets appears
to be limited at least in part by loss of surface properties of the
blanket. In particular, such blankets are generally coated with a
release layer, preferably a silicone release material. It appears
that the release properties of the release material deteriorates
with use.
[0006] In U.S. Pat. No. 5,192,638, the specification of which is
incorporated herein in its entirety, Landa et al introduced a new
liquid toner comprising a carrier liquid such as a light mineral
oil and pigmented toner particles having fibrous extensions. The
mineral oils described in the above referenced patent were ISOPAR L
and M (TM) type saturated hydrocarbon liquids having a high
Kauri-Butanol number and a high resistivity. Many other mineral
oils such as MARCOL 82 or other carrier liquids for liquid toner as
are known in the art, are also suitable for the toner type of U.S.
Pat. No. 5,192,638, depending on the overall characteristics
specified for the toner. MARCOL 82 has a very low volatility and
images produced from toners that use Marcol 82 generally have poor
abrasion resistance.
[0007] A characteristic of these toners is that they solvate the
carrier liquid at elevated temperatures but are substantially
insoluble in the carrier liquid at room temperature. Other patents
and publications that describe preferred embodiments of this toner
type and additives useful in the toner are U.S. Pat. Nos.
5,300,390; 5,286,593; 5,208,130; 5,266,435; 5,264,313; and
5,225,306 and in PCT publications WO 94/02887 the disclosures of
which are incorporated herein by reference.
SUMMARY OF THE INVENTION
[0008] The present invention seeks to provide, in one aspect
thereof, improved image transfer apparatus using an intermediate
transfer member and a liquid toner and having an improved longevity
of the intermediate transfer member.
[0009] The present invention further seeks to provide, in a second
aspect thereof, an improved liquid toner that, when used with an
intermediate transfer member results in an improvement in the life
of the intermediate transfer member over what it would have been
with prior art toners.
[0010] The present invention further seeks to provide, in a third
aspect thereof, liquid toner components for use in the liquid toner
of the invention.
[0011] There is thus provided in accordance with a preferred
embodiment of the invention, imaging apparatus comprising:
[0012] an imaging surface having a liquid toner image formed
thereon, said image comprising toner particles and carrier liquid,
wherein the carrier liquid comprises as a major component, a
liquid, preferably a liquid hydrocarbon, that evaporates relatively
quickly at room temperature, and as a minor component, a liquid,
preferably a liquid hydrocarbon, that evaporates relatively slowly
at room temperature; and
[0013] an intermediate transfer member having a release outer layer
that receives the toner image from the imaging surface and from
which it is subsequently transferred.
[0014] There is further provided in accordance with a preferred
embodiment of the invention, an imaging apparatus comprising:
[0015] an imaging surface having a liquid toner image formed
thereon, said image comprising fibrous toner particles and carrier
liquid, said fibrous toner particles comprising a polymer portion
and pigment dispersed in said polymer portion, said polymer portion
comprising a surface of said fibrous toner particles and being
insoluble in said carrier liquid at temperatures below 40.degree.
C. so that the polymer portion will not dissolve or solvate in
storage, and solvatable by said carrier liquid only at temperatures
above 50.degree. C., and said carrier liquid comprising, as a major
component, first liquid hydrocarbon having a first rate of
evaporation, and, as a minor component, second liquid hydrocarbon
having a second rate of evaporation which, at room temperature, is
at least an order of magnitude less than the first rate of
evaporation; and
[0016] an intermediate transfer member having a release outer layer
that is capable of receiving toner images from the imaging surface
and subsequently transferring the images to a further surface.
[0017] Preferably, the release outer layer solvates the carrier
liquid and is swelled by it.
[0018] There is further provided in accordance with a preferred
embodiment of the invention a liquid developer comprising:
[0019] toner particles; and
[0020] carrier liquid, wherein the carrier liquid comprises as a
major component, a liquid, preferably a liquid hydrocarbon, that
evaporates relatively quickly at room temperature, and as a minor
component, a liquid, preferably a liquid hydrocarbon, that
evaporates very slowly at room temperature.
[0021] There is further provided in accordance with a preferred
embodiment of the invention, a liquid toner comprising:
[0022] fibrous toner particles and carrier liquid;
[0023] said carrier liquid comprising, as a major component, first
liquid hydrocarbon having a first rate of evaporation, and, as a
minor component, second liquid hydrocarbon having a second rate of
evaporation which, at room temperature, is at least an order of
magnitude less than the first rate of evaporation; and
[0024] said fibrous toner particles comprising a polymer portion
and pigment dispersed in said polymer portion, said polymer portion
comprising a surface of said fibrous toner particles and being
insoluble in said carrier liquid at temperatures below 40.degree.
C. so that the polymer portion will not dissolve or solvate in
storage, and solvatable by said carrier liquid only at temperatures
above 50.degree. C.
[0025] Preferably, said minor component comprises between 0.2 and
2% and wherein said major component comprises between 98% and 99.7%
of the total amount of said carrier liquid.
[0026] Preferably, the major component evaporates at least about an
order of magnitude more quickly than the minor component.
[0027] Preferably, the major component has a vapor pressure at
100.degree. F. of greater than 0.05 psia when measured according to
ASTM standard D 2879.
[0028] There is further provided, in accordance with a preferred
embodiment of the invention, a mixture of liquid hydrocarbons
substantially comprising between 0.5 and 4% of a substantially
non-conducting liquid, preferably, a liquid hydrocarbon, that
evaporates very slowly at room temperature and between 96 and 99.5
percent by weight of a substantially non-conducting liquid,
preferably a liquid hydrocarbon, that evaporates at least an order
of magnitude more quickly.
[0029] Preferably, the mixture further comprises a charge director
for liquid toner particles.
[0030] In a preferred embodiment of the invention, the carrier
liquids are hydrocarbons wherein the hydrocarbon that evaporates
relatively quickly has a vapor pressure at 100.degree. F. of
greater than 0.05 psia when measured according to ASTM standard D
2879 and a 95% evaporation time at room temperature of less than 10
hours, preferably, less than 6 hours and the liquid hydrocarbon
that evaporates relatively slowly has an evaporation time at least
about an order of magnitude greater than 10 hours. Alternatively,
other carrier liquids suitable for use in liquid toners such as
fluorocarbons, silicones, etc., may be used in the practice of the
broadest aspects of the invention.
[0031] In a preferred embodiment of the invention the release
coating absorbs the carrier liquid and is swelled by it.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The present invention will be understood and appreciated
more fully from the following detailed description, taken in
conjunction with the drawings in which:
[0033] FIG. 1 is a simplified sectional illustration of
electrostatic imaging apparatus constructed and operative in
accordance with a preferred embodiment of the present
invention;
[0034] FIG. 2 is a-simplified enlarged sectional illustration of
the apparatus of FIG. 1;
[0035] FIG. 3A is a simplified, cross-sectional side view of an
intermediate transfer member, including a removable intermediate
transfer blanket mounted on a drum, in accordance with a preferred
embodiment of the invention;
[0036] FIG. 3B is a partially cut-away top view of the intermediate
transfer member of FIG. 3A;
[0037] FIGS. 4A and 4B are respective top and side views of an
intermediate transfer blanket in accordance with a preferred
embodiment of the invention;
[0038] FIG. 4C shows details of the layered construction of the
intermediate transfer blanket in accordance with a preferred
embodiment of the invention;
[0039] FIG. 4D is a cut-away expanded view, taken along line IV-D
of FIG. 4A, of a securing mechanism on the intermediate transfer
blanket of FIGS. 4A and 4B; and
[0040] FIG. 5 is a simplified cross-sectional illustration of a
portion of an intermediate transfer member, including a removable
intermediate transfer blanket mounted on a drum in accordance with
another preferred embodiment of the invention.
[0041] FIG. 6 shows a layered intermediate transfer blanket in
accordance with a preferred embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0042] Reference is now made to FIGS. 1 and 2 which illustrate a
multicolor electrostatic imaging system constructed and operative
in accordance with a preferred embodiment of the present invention.
As seen in FIGS. 1 and 2 there is provided an imaging sheet,
preferably an organic photoreceptor 12, typically mounted on a
rotating drum 10. Drum 10 is rotated about its axis by a motor or
the like (not shown), in the direction of arrow 18, past charging
apparatus 14, preferably a corotron, scorotron or roller charger or
other suitable charging apparatus as are known in the art and which
is adapted to charge the surface of sheet photoreceptor 12. The
image to be reproduced is focused by an imager 16 upon the charged
surface 12 at least partially discharging the photoconductor in the
areas struck by light, thereby forming the electrostatic latent
image. Thus, the latent image normally includes image areas at a
first electrical potential and background areas at another
electrical potential.
[0043] Photoreceptor sheet 12 may use any suitable arrangement of
layers of materials as is known in the art, however, in the
preferred embodiment of the photoreceptor sheet, certain of the
layers are removed from the ends of the sheet to facilitate its
mounting on drum 10.
[0044] This preferred photoreceptor sheet and preferred methods of
mounting it on drum 10 are described in a co-pending application of
Belinkov et al., IMAGING APPARATUS AND PHOTORECEPTOR THEREFOR,
filed Sep. 7, 1994, assigned Ser. No. 08/301,775, now U.S. Pat. No.
5,508,790 the disclosure of which is incorporated herein by
reference. Alternatively, photoreceptor 12 may be deposited on the
drum 10 and may form a continuous surface. Furthermore,
photoreceptor 12 may be a non-organic type photoconductor based,
for example, on a compound of Selenium.
[0045] Imaging apparatus 16 may be a modulated laser beam scanning
apparatus, an optical focusing device for imaging a copy on a drum
or other imaging apparatus such as is known in the art.
[0046] Also associated with drum 10 and photoreceptor sheet 12, in
the preferred embodiment of the invention, are a multicolor liquid
developer spray assembly 20, a developing assembly 22, color
specific cleaning blade assemblies 34, a background cleaning
station 24, an electrified squeegee 26, a background discharge
device 28, an intermediate transfer member 30, cleaning apparatus
32, and, optionally, a neutralizing lamp assembly 36.
[0047] Developing assembly 22 preferably includes a development
roller 38. Development roller 38 is preferably spaced from
photoreceptor 12 thereby forming a gap therebetween of typically 40
to 150 micrometers and is charged to an electrical potential
intermediate that of the image and background areas of the image.
Development roller 38 is thus operative, when maintained at a
suitable voltage, to apply an electric field to aid development of
the latent electrostatic image.
[0048] Development roller 38 typically rotates in the same sense as
drum 10 as indicated by arrow 40. This rotation provides for the
surface of sheet 12 and development roller 38 to have opposite
velocities at the gap between them.
[0049] Multicolor liquid developer spray assembly 20, whose
operation and structure is described in detail in U.S. Pat. No.
5,117,263, the disclosure of which is incorporated herein by
reference, may be mounted on axis 42 to allow assembly 20 to be
pivoted in such a manner that a spray of liquid toner containing
electrically charged pigmented toner particles can be directed
either onto a portion of the development roller 38, a portion of
the photoreceptor 12 or directly into a development region 44
between photoreceptor 12 and development roller 38. Alternatively,
assembly 20 may be fixed. Preferably, the spray is preferably
directed onto a portion of the development roller 38.
[0050] Color specific cleaning blade assemblies 34 are operatively
associated with developer roller 38 for separate removal of
residual amounts of each colored toner remaining thereon after
development. Each of blade assemblies 34 is selectably brought into
operative association with developer roller 38 only when toner of a
color corresponding thereto is supplied to development region 44 by
spray assembly 20. The construction and operation of cleaning blade
assemblies is described in PCT Publication WO 90/14619 and in U.S.
Pat. No. 5,289,238, the disclosures of which are incorporated
herein by reference.
[0051] Each cleaning blade assembly 34 includes a toner directing
member 52 that serves to direct the toner removed by the cleaning
blade assemblies 34 from the developer roller 38 to separate
collection containers 54, 56, 58, and 60 for each color to prevent
contamination of the various developers by mixing of the colors.
The toner collected by the collection containers is recycled to a
corresponding toner reservoir (55, 57, 59 and 61). A final toner
directing member 62 always engages the developer roller 38 and the
toner collected thereat is supplied into collection container 64
and thereafter to reservoir 65 via separator 66 that is operative
to separate relatively clean carrier liquid from the various
colored toner particles.
[0052] The separator 66 may be typically of the type described in
U.S. Pat. No. 4,985,732, the disclosure of which is incorporated
herein by reference.
[0053] In a preferred embodiment of the invention, as described in
U.S. Pat. No. 5,255,058, the disclosure of which is incorporated
herein by reference, where the imaging speed is very high, a
background cleaning station 24 typically including a reverse roller
46 and a fluid spray apparatus 48 is provided. Reverse roller 46
which rotates in a direction indicated by arrow 50 is electrically
biased to a potential intermediate that of the image and background
areas of photoconductive drum 10, but different from that of the
development roller. Reverse roller 46 is preferably spaced apart
from photoreceptor sheet 12 thereby forming a gap therebetween that
is typically 40 to 150 micrometers.
[0054] Fluid spray apparatus 48 receives liquid toner from
reservoir 65 via conduit 88 and operates to provide a supply of
preferably non-pigmented carrier liquid to the gap between sheet 12
and reverse roller 46. The liquid supplied by fluid spray apparatus
48 replaces the liquid removed from drum 10 by development assembly
22 thus allowing the reverse roller 46 to remove charged pigmented
toner particles by electrophoresis from the background areas of the
latent image. Excess fluid is removed from reverse roller 46 by a
liquid directing member 70 that continuously engages reverse roller
46 to collect excess liquid containing toner particles of various
colors which is in turn supplied to reservoir 65 via a collection
container 64 and separator 66.
[0055] The apparatus embodied in reference numerals 46, 48, 50 and
70 is not required for low speed systems, but is preferably
included in high speed systems.
[0056] Preferably, an electrically biased squeegee roller 26 is
urged against the surface of sheet 12 and is operative to remove
liquid carrier from the background regions and to compact the image
and remove liquid carrier therefrom in the image regions. Squeegee
roller 26 is preferably formed of resilient slightly conductive
polymeric material as is well known in the art, and is preferably
charged to a potential of several hundred to a few thousand volts
with the same polarity as the polarity of the charge on the toner
particles.
[0057] Discharge device 28 is operative to flood the sheet 12 with
light that discharges the voltage remaining on sheet 12, mainly to
reduce electrical breakdown and improve transfer of the image to
intermediate transfer member 30. Operation of such a device in a
write black system is described in U.S. Pat. No. 5,280,326, the
disclosure of which is incorporated herein by reference.
[0058] FIGS. 1 and 2 further show that multicolor toner spray
assembly 20 receives separate supplies of colored toner typically
from four different reservoirs 55, 57, 59 and 61. FIG. 1 shows four
different colored toner reservoirs 55, 57, 59 and 61 typically
containing the colors Yellow, Magenta, Cyan and, optionally, Black
respectively. Pumps 90, 92, 94 and 96 may be provided along
respective supply conduits 98, 101, 103 and 105 for providing a
desired amount of pressure to feed the colored toner to multicolor
spray assembly 20. Alternatively, multicolor toner spray assembly
20, which is preferably a three level spray assembly, receives
supplies of colored toner from up to six different reservoirs (not
shown) which allows for custom colored tones in addition to the
standard process colors.
[0059] Additionally, in response to measurements of the liquid
toner in reservoirs 55, 57, 59 and 61, toner concentrate from
concentrate containers 84, charge director concentrate from
containers 82 and replenishment liquid from container 86 are added
to the respective reservoirs. In particular, as is well known in
the art, toner concentrate is added to the reservoirs in response
to a reduced concentration of toner particles in the reservoirs. As
is well known in the art, such concentration is preferably measured
optically. Charge director Is added in response to reduced
conductivity of the toner in the reservoirs. Replenishment liquid
is added in response to a reduction in the volume of liquid in the
reservoirs.
[0060] A preferred type of toner for use with the present invention
is that described in Example 1 of U.S. Pat. No. 4,794,651, the
disclosure of which is incorporated herein by reference or variants
thereof as are well known in the art and as are described in the
patents, applications and publications listed in the Background of
the Invention. Preferably the liquid toner is manufactured by one
of the methods described in these patents applications and
publications. For colored liquid developers, carbon black is
replaced by color pigments as is well known in the art. Other
liquid toners may alternatively be employed.
[0061] While the invention is useful for a wide range of toner
types preferred toners of the present invention have the following
formulations:
[0062] Black toner--about 16% NUCREL 925 (ethylene copolymer by
DUPONT), about 0.4% BT583D (blue pigment produced by Cookson
Pigments), about 4% MOGUL L carbon black (Cabot), approximately
0.45% aluminum tristearate and charge director as described in U.S.
patent application Ser. No. 07/915,291 (utilizing lecithin, BBP and
ICI G3300B) and in WO 94/02887 in an amount equal to 40 mg/gm of
solids and the remainder 99.5% ISOPAR L and 0.5% MARCOL 82.
[0063] Magenta toner--about 15.5% BYNELL 2002 (ethylene terpolymer
by DUPONT), about 2.8% FINESS Re F2B magenta pigment (Toyo Ink),
about 0.14% SICO FAST YELLOW D1355DD yellow Pigment (BASK)
approximately 0.45% aluminum tristearate and charge director as
described in U.S. patent application Ser. No. 07/915,291, now U.S.
Pat. No. 5,346,796 (utilizing lecithin, BBP and ICI G3300B) and in
WO 94/02887 in an amount equal to 40 mg/gm, of solids and the
remainder 99.5% ISOPAR L and 0.5% MARCOL 82.
[0064] Cyan toner has a composition similar to that of the magenta
toner except that 2.36% of BT583D pigment (Cookson replaces the
magenta pigment and the yellow pigment is reduced to 0.03%. The
composition of the yellow toner is similar to that of the black
toner except that 3.13% of yellow pigment is substituted for the
pigment and carbon black of the black toner.
[0065] It should be understood that the invention is not limited to
the specific type of image forming system used and the present
invention is also useful with any suitable imaging system that
forms a liquid toner image on an image forming surface and
transfers the image to an intermediate transfer member for
subsequent transfer to a final substrate.
[0066] The specific details given above for the image forming
system are included as part of a best mode of carrying out the
invention, however, many aspects of the invention are applicable to
a wide range of systems as known in the art for printing and
copying using liquid toners.
[0067] Intermediate transfer member 30, an especially preferred
embodiment of which is described the above referenced application
of EDAN et al., may be any suitable intermediate transfer member
having a multilayered transfer portion such as those described in
the U.S. patents and patent applications incorporated above by
reference. Furthermore, the blanket may be replaceable as described
in the EDAN et al. application and may be mounted by any convenient
means on the drum. Preferred mounting means for the blanket is
shown in the EDAN et al. application. FIGS. 3A, 3B and 4A-4D
illustrate a preferred embodiment of intermediate transfer member
30 in accordance with a preferred embodiment of the invention. FIG.
3A shows an intermediate transfer blanket 100 mounted on a drum
102. Transfer blanket 100 (whose details are shown in FIGS. 4C and
4D) comprises a preferably layered transfer portion 104 and a
mounting fitting 106.
[0068] As shown most clearly in FIG. 4C, transfer portion 104
comprises a release layer 109 which is outermost on the blanket
when it is mounted on drum 102. Underlying layer 109 is a
conforming layer 111 preferably of a soft elastomer, preferably of
polyurethane and preferably having a Shore A hardness of less than
about 65, more preferably, less than about 55, but preferably more
than about 35. A suitable hardness value is between 45-55,
preferably about 50. Underlying layer 111 is a conductive layer 114
which overlays a blanket body 116 comprising a top layer 118, a
compressible layer 120 and a fabric layer 122. Underlying the
fabric layer is an adhesive layer 126 which is in contact with drum
102.
[0069] Drum 102 is preferably heated by an internal halogen lamp
heater or other heater to aid transfer of the image to and from the
release layer 109 to a final substrate as is well known in the art.
Other heating methods, or no heating at all, may also be used in
the practice of some aspects of the invention. The degree of
heating will depend on the characteristics of the toner and or ink
used in conjunction with the invention.
[0070] As shown in FIGS. 4A, 4B and 4D, mounting fitting 106
comprises an elongate electrically conducting bar 108, for example
of a metal such as aluminum formed with a series of L-shaped
mounting legs 110 (in the form of finger-like extensions) which are
also conducting, preferably of the same material as bar 108, and
preferably formed integrally therewith. In particular, bar 108 is
formed with a slot into which the end of layered transfer portion
104 is inserted. Preferably, the end of the layered portion which
is inserted into the mounting bar does not have a release layer 109
or conforming layer 111, whereby conducting layer 114 is exposed
and is therefore in electrical contact with bar 108. Alternatively,
the bar 108 can be formed with sharp internal projections which
pierce the outer layers of the blanket and contact the conducting
layer.
[0071] Optionally, each of the layers beneath the conducting layer
114 may be partially conducting (for example, by the addition of
conductive carbon black or metal fibers) and the adhesive layer may
be conductive, such that current also flows directly from the drum
surface to the conducting layer.
[0072] In one preferred embodiment of the invention, fitting 106 is
formed of a single sheet of metal, wherein the legs are partially
cut from the metal which is bent into a U shape to form the slot
into which the layered portion is inserted. After insertion, the
outer walls of the slot are forced against the layered portion to
secure the layered portion in the slot. The partially cut out
portion is bent to form the mounting legs.
[0073] In the preferred embodiment of the invention shown in FIG.
3A, drum 102 is maintained at a potential suitable for transferring
images to the intermediate transfer member, for example at 500
volts, which voltage is applied, via mounting fitting 106 to
conductive layer 114. Thus, the source of transfer voltage is very
near the outer surface of portion 104 which allows for a lower
transfer potential on the drum.
[0074] In a preferred embodiment of the invention, transfer portion
104 is fabricated by the following procedure:
[0075] 1--The starting structures for blanket construction is a
blanket body 116 generally similar to that generally used for
printing blankets. One suitable body is MCC-1129-02 manufactured
and sold by Reeves SpA, Lodovicio (Milano), Italy. Other preferred
blanket types are described the parents of this application. In a
preferred embodiment of the invention, body 116 comprises a fabric
layer 122, preferably of woven NOMEX material and having a
thickness of about 200 micrometers, a compressible layer 120,
preferably comprising about 400 micrometers of saturated nitrite
rubber loaded with carbon black to increase its thermal
conductivity. Layer 120 preferably contains small voids (about
40-60% by volume) and a top layer 118 preferably comprised of the
same material as the compressible layer, but without voids. Layer
118 is preferably about 100 micrometers thick. The blanket body is
produced by manufacturing methods as are generally used for the
production of offset printing blankets for ink offset printing.
[0076] Blanket body 116 is preferably sized to a relatively exact
thickness by abrading portions of the surface of top layer 118. A
preferred thickness for the finished body 116 is about 700
micrometers, although other thicknesses are useful, depending on
the geometry of the printing system in which it is used and the
exact materials used in the blanket body.
[0077] 2--The fabric side of blanket body 116 is preferably coated
with a 30 micrometer thick coating of silicone based adhesive
(preferably, Type D 66 manufactured by Dow Corning). The adhesive
is covered with a sheet of mylar coated with a fluorosilicone
material, such as DP 5648 Release Paper (one side coat) distributed
by H. P. Smith Inc., Bedford Park, Ill. This adhesive to
characterized by its good bond to the surface of drum 102 and is
resistant to the carrier liquid used in the liquid toner. The
blanket may be removed from the drum, when its replacement is
desired, by cutting the blanket along the edge of fitting 106 and
removing the blanket and fitting.
[0078] An adhesive is used to assure good thermal contact between
the bade of the blanket and the drum on which it is mounted. A
silicone adhesive is used since adhesives normally used in
attachment of blankets deteriorate under the heat which is
generated is the underlying drum in the preferred apparatus. While
the temperature of the drum varies, depending on the thermal
resistance of the blanket and the desired surface temperature of
the blanket (which in turn depends on the toner used in the process
and the details of transfer of the toner to the final substrate),
the drum temperature may reach 80.degree. C., 100.degree. C.,
120.degree. C. or 150.degree. C. or more.
[0079] 3--The top layer is coated with a sub-micron layer of primer
before being coated with the conductive layer. A preferred primer
is Dow Corning 1205 Prime Coat. The type of primer depends on the
properties of the top layer and of the conductive layer.
Preferably, 0.3 micron of primer is coated onto a clean top layer
with a No. 0 bar in a wire coating apparatus and is allowed to dry
before applying the conductive layer.
[0080] 4--Conductive layer 114 is preferably formed of acrylic
rubber loaded with conductive carbon black. In a preferred
embodiment of the invention only 2-3 micrometers of conductive
coating are required. The conductive layer is formed by first
compounding 300 grams of HYTEMP 40SIEF (B. F. Goodrich) with 6
grams of HYTEMP NPC 50 (B. F. Goodrich) and 9 grams of sodium
stearate in a two roll still for 20 minutes, dissolving 150 grams
of the compounded material in 2000 grams of methyl ethyl ketone
(MEK) by stirring for 12 hours at room temperature.
[0081] 40 grams of conductive carbon black, such as for example,
Printer XE2 (Degussa) are added to the solution and the mixture is
ground in a 01 attritor (Union Process) loaded with {fraction
(3/16)}" steel balls. Grinding proceeds at 10.degree. C. for 4
hours after which time the material is diluted by the addition of
MSR to a concentration of 9.5-8t solids and discharged from the
grinder in the form of a conductive lacquer.
[0082] The primed blanket is overcoated with about 3 micrometers of
the conductive lacquer (three passes using a No. 0 rod) and allowed
to dry for 5 minutes at room temperature.
[0083] An additional coating of primer is added over the conductive
lacquer (except for the portion which is to be inserted into bar
108) before the soft elastomeric conforming layer is applied.
[0084] The resistance of the conductive layer should preferably be
more than about 20 kohms/square and preferably less than about 50
kohm/square. This value will depend on the resistivity of the
layers above the conducting layer and on the aspect ratio of the
blanket. In general, the resistance should be low enough so that
the current flowing on the conducting layer (to supply leakage
current through the overlying layers) should not cause a
substantial variation of voltage along the surface of the blanket.
The resistance of the conducting layer and, more importantly, the
resistance of the overlying layers controls the current flowing
through the overlying layers. Generally speaking the conductive
layer has a relatively low resistance and resistivity, the
conforming layer (layer 111) has a higher resistivity and the
overlying release layer (layer 109) has a still higher
resistivity.
[0085] 5--One kg of pre-filtered FOMREZ-50 Polyurethane resin
(Hagalil Company, Ashdod, Israel) is dehydrated and degassed under
vacuum at 60.degree. C. 600 grams of the degassed material is mined
with 1.4 grams of di-butyl-tin-diluarate (Sigma) and degassed at
room temperature for 2 hours. 30 grams of the resulting material
3.15 grams of RTV Silicone 118 (General Electric), 4.5 grams of
Polyurethane cross-linker, MDI D6530 (Bayer) and are stirred
together. A 100 micrometer layer of the material is coated over the
primed conductive layer using a No. 3 wire rod with several passes
under clean conditions, preferably, class 100 conditions. The
coating is cured for two hours at roan temperature under a clean
hood.
[0086] Other methods of forming suitable conforming layers are
shown and described in the parents of thin application.
[0087] Layer 111 which is thus formed should have a resistance of
the order of about 109 ohm-cm, good thermal stability at the
working temperature of the blanket, which is preferably about
100.degree. C. or less.
[0088] The function of the conforming layer is to provide good
conformation of the blanket to the image forming surface (and the
image on the image forming surface) at the low pressures used in
transfer of the image from the image forming surface to the
blanket. The layer should have a Shore A hardness preferably of
between 25 or 30 and 65, more preferably about 50. While a
thickness of 100 micrometers is preferred, other thicknesses,
between 50 micrometers and 300 micrometers can be used, with 75 to
125 micrometers being preferred.
[0089] 6--12 grams of RTV silicone 236 (Dow Corning) release
material diluted with 2 grams of ISOPAR.RTM. L petroleum distillate
(Exxon) and 0.72 grams of SYL-OFF 297 (Dow Corning) are mixed
together. A wire rod (bar No. 1) coating system is used, with five
or six passes, under clean conditions to achieve an 8 micrometer
release layer thickness. The material is cured at 140.degree. C.
for two hours. The cured release material has a resistivity of
between about 10.sup.14 and 10.sup.15 ohm-cm.
[0090] In order to mount blanket 100 on drum 102, mounting legs 110
are inserted into a plurality of mounting holes 130 formed in drum
102, preferably without removing the mylar sheet from the adhesive
layer (the back of the blanket). As can be seen most clearly in
FIG. 4D, mounting legs 110 each have a tip portion 132 and a back
portion 134. Tips 132 are inserted into slots formed in the far
sidewalls of mounting holes 130 and the back portion 134 rests
against the opposite sidewall of the hole. In this way the end of
the blanket is accurately positioned. The edge of the mylar sheet
closest to the legs is removed and the remainder of the mylar sheet
is progressively removed while making sure that the successive
portions of the blanket which are thus attached to the drum by the
adhesive lie flat against the drum.
[0091] The present inventors have found that this method of
mounting is far superior to either adhesive mounting alone or to
grippers at both ends of the blanket in providing a stable transfer
surface.
[0092] As an alternative to, or additional to, the adhesive layer
126, a very soft conforming layer may be used at the back of the
blanket. A soft layer of this type will allow for good thermal
contact between the blanket and-the heated 102 so that the
temperature of the drum need not be excessive in order for the
outer surface of the blanket to reach its operating temperature.
Furthermore, such a very soft layer will cause the blanket to
"cling" to the drum obviating the use of adhesive under certain
circumstances. Furthermore, when the blanket is replaced there is
no adhesive residue on the drum to be removed.
[0093] A very soft layer may be produced by the following
method:
[0094] 1--100Q of HI-TEMP 4051 EP (Zeon) acrylic resin is mixed
with 2 g NPC-50 crosslinker (Zeon) and 3 g sodium stearate and
dissolved in toluene to give a solution of 15% non-volatile solids.
Optionally, up to about 40 g of carbon black Pearls 130 (Cabot) is
added.
[0095] 2--A thin layer of the solution is coated onto release
coated mylar and dried. This process is repeated several times
until a thickness of preferably 20-30 micrometers is achieved.
[0096] 3--The uncured resin is laminated to the adhesive layer of a
blanket produced in accordance with the invention, or directly to
the fabric layer. This step is preferably carried out prior to the
cure of the release layer.
[0097] 4 --The laminated structure is cured together with the
release layer and the release coated mylar is removed.
[0098] The layer has a Shore A hardness of about 20-24 without
carbon black and about 40-45 with carbon blank. Softer materials
are also suitable; however, substantially harder materials do not
adhere well to the drum surface. Optionally, the adhesive layer at
the trailing end of the blanket is not coated with the very soft
layer to improve coherence of the blanket and the drum. This is
especially desirable for harder layers.
[0099] The acrylic material may be replaced `by other soft
elastomer materials such as soft polyurethane or nitrile rubber.
Other heat improving fillers which have a smaller effect on the
hardness of the final product may be used instead of carbon black,
such as Fe.sub.2O.sub.3 or alpha aluminum oxide.
[0100] FIG. 5 shows an alternative, preferred embodiment of the
invention in which somewhat different shaped holes 130' are used.
In this embodiment the back portion 134 rests against a protrusion
150 formed on one side of the hole while a back surface 152 of leg
110 rests against the bottom 156 of a protrusion formed on the
other side of the hole.
[0101] While the preferred electrical connection between the
conductive layer and the mounting bar is preferably achieved by
removing (or not forming) the layers which overly an end portion of
the conductive layer, piercing the overlying layers, for example by
crimping and or piercing the mounting bar for example at points
marked 160 in FIG. 4D. Crimping can also be used to hold the
blanket in the mounting bar.
[0102] While the adhesive layer preferably covers the back of the
blanket, alternatively the adhesive layer may cover only a portion
of the back such as the edge farthest away from the bracket (the
trailing edge of the blanket), or may for some embodiments of the
invention and under certain circumstances be omitted.
[0103] Member 30 is maintained at a suitable voltage and
temperature for electrostatic transfer of the image thereto from
the image bearing surface. Intermediate transfer member 30 is
preferably associated with a pressure roller 71 for transfer of the
image onto a final substrate 72, such as paper, preferably by heat
and pressure.
[0104] Cleaning apparatus 32 is operative to scrub clean the
surface of photoreceptor 12 and preferably includes a cleaning
roller 74, a sprayer 76 to spray a non polar cleaning liquid to
assist in the scrubbing process and a wiper blade 78 to complete
the cleaning of the photoconductive surface. Cleaning roller 74
which may be formed of any synthetic resin known in the art for
this purpose is driven in the same sense as drum 10 as indicated by
arrow 80, such that the surface of the roller scrubs the surface of
the photoreceptor. Any residual charge left on the surface of
photoreceptor sheet 12 may be removed by flooding the
photoconductive surface with light from optional neutralizing lamp
assembly 36, which may not be required in practice.
[0105] In accordance with a preferred embodiment of the invention,
after developing each image in a given color, the single color
image is transferred to intermediate transfer member 30 which
comprises a transfer blanket 100 preferably mounted on a drum 102.
Subsequent images in different colors are sequentially transferred
in alignment with the previous image onto intermediate transfer
member 30. When all of the desired images have been transferred
thereto, the complete multi-color image is transferred from
transfer member 30 to substrate 72. Impression roller 71 only
produces operative engagement between intermediate transfer member
30 and substrate 72 when transfer of the composite image to
substrate 72 takes place. Alternatively, each single color image is
separately transferred to the substrate via the intermediate
transfer member. In this case, the substrate is fed through the
machine once for each color or is held on a platen and contacted
with intermediate transfer member 30 during image transfer.
[0106] Drum 102 is preferably heated by an internal halogen lamp
heater or other heater to aid transfer of the image to and from the
release layer 109 (FIG. 6) to a final substrate as is well known in
the art. Other heating methods, or no heating at all may also be
used in the practice of some aspects of the invention. The degree
of heating will depend on the characteristics of the toner and or
ink used in conjunction with the invention.
[0107] FIG. 6 illustrates the salient feature of intermediate
transfer member 30 in accordance with a preferred embodiment of the
invention. FIG. 6 shows a cross section of a multi-layer
intermediate transfer mounted on a drum 102. Transfer blanket 100
(whose details are given in the above mentioned EDAN patent
application, but which are not particularly relevant to the present
invention) has, as a salient feature, a layered base portion 116
and release layer 109 that receives the liquid toner images from
the intermediate transfer member and from which they are
transferred to the final substrate.
[0108] In a preferred embodiment of the invention the release layer
is formed by diluting 6-12 grams of RTV silicone 236 (Dow Corning)
release material with 2 grams of ISOPAR L (Exxon) and mixing the
result with 0.72 grams of SYL-OFF 297 (Dow Corning). A wire rod
(bar No. 1) coating system is used, with five or six passes, under
clean conditions to achieve an 8 micrometer release layer
thickness. The material is cured at 140.degree. C. for two hours.
The cured release material has a resistivity of between about
10.sup.14 and 10.sup.15 ohm-cm.
[0109] In a preferred embodiment of the invention, the liquid toner
in reservoirs 55, 57, 59 and 61 ("the toner reservoirs") comprises
approximately 1%-2% of toner particles by weight, additives as are
known in the art and a relatively volatile hydrocarbon carrier
liquid. This liquid can be characterized as being composed mainly
of a carrier liquid that evaporates quickly and having less than
2%, preferably 0.2%-2%, more preferably 0.5%-1%, of a very slowly
evaporating component. In a preferred embodiment of the invention,
the carrier liquids are hydrocarbons wherein the hydrocarbon that
evaporates relatively quickly has a vapor pressure at 100.degree.
F. of greater than 0.05 psia when measured according to ASTM
standard D 2879 and a 95% evaporation time at room temperature of
less than 10 hours, preferably, less than 6 hours and the liquid
hydrocarbon that evaporates relatively slowly has an evaporation
rate much greater than 10 hours. In particular, the slowly
evaporating hydrocarbon has an evaporation rate of about an order
of magnitude slower than that of the relatively evaporating
material.
[0110] The present inventors have found that addition of such small
percentages of a hydrocarbon with a low volatility results in a two
to three fold increase in the lifetime of the release surface of
the blanket. While this phenomena is not completely understood, it
is believed that during transfer of the image, by the intermediate
transfer member, to the final substrate, carrier liquid is absorbed
onto the surface of-the blanket. The heating of the blanket
described above causes the higher volatility component to
evaporate, while leaving a coating of the lower volatility
component as a protective coating on the blanket surface. While the
lower volatility component is also evaporated from the blanket, due
to the differences in volatility, the layer is replenished by
succeeding imaging cycles so that the layer remains substantially
of lower volatility component.
[0111] The use of higher proportions of low volatility component is
proscribed by its effect on the quality of the fusing of the image
to the final substrate, and especially by the reduction in abrasion
resistance that results. On the other hand as the proportion of low
volatility component decreases, the increase in life of the blanket
is believed to be reduced.
[0112] In a preferred embodiment of the invention the relatively
higher volatility component is ISOPAR L (EXXON) and the relatively
lower volatility component is MARCOL 82 (EXXON). Other high and low
volatility components may be used, and the choice of component
volatility and percentage in the carrier liquid will depend in some
measure on the speed of the imaging process, the amount of carrier
liquid in the image and background portions of the image
transferred to and from the intermediate transfer member and the
temperature of the member.
[0113] The small percentage of low volatility component can be
incorporated into the liquid toner in a number of ways. One way is
to add the desired proportion of low volatility component to the
carrier liquid present in the concentrate, in the charge director
concentrate and in the replenishment liquid. Alternatively, a
higher percentage of low volatility component can be added to
either the toner concentrate or the replenishment liquid,
preferably to the replenishment liquid. It has been found that a
replenishment liquid having 1% of MARCOL 82 to 99% ISOPAR L works
well. Other proportions, such as 0.5% to 4% MARCOL 82 are also
believed to give satisfactory results, however, between 1% and 2%
Marcol 82 is preferred.
[0114] It will be appreciated by persons skilled in the art that
the present invention is not limited by the description and example
provided hereinabove. Rather, the scope of this invention is
defined only by the claims which follow:
* * * * *